Electrical outlet box

ABSTRACT

An electrical outlet box assembly provides for the accommodation of dual voltage fixtures. The outlet box assembly accommodates electrical fixtures and data fixtures along separate mounting axes. The electrical outlet box assembly provides for increased capacity while meeting applicable code requirements.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of Ser. No. 10/083,724 filed Feb. 25,2002 now U.S. Pat. No. 6,727,428, which claims priority to Ser. No.60/272,129, filed on Feb. 28, 2001.

FIELD OF THE INVENTION

The present invention relates generally to an electrical outlet box forhousing electrical fixtures such as a switch or a receptacle. Moreparticularly, the present invention relates to an improved electricaloutlet box providing for the accommodation of dual voltage fixtures.

BACKGROUND OF THE INVENTION

It has long been known to house electrical fixtures such as switches andreceptacles in an electrical outlet box. The outlet box permits theinsertion of electrical wires into the box which are terminated toelectrical fixtures. The fixtures then may be mounted to the box whichprovides protection to the fixtures as well as the wires terminatedtherein. The outlet box is then mounted to a wall stud at a convenientlocation to provide access. Most outlet boxes accommodate one or moreelectrical fixtures which terminate standard 110 volt electrical wires.

It has also become necessary to terminate communications wires for suchpurposes as data, voice and signal transmission. While terminations arenot required to be housed in an electrical box, as are electricalterminations such as switch and receptacles, aesthetics and convenientusage has dictated the need to place the communication terminations inclose proximity to the electrical terminations.

The art has developed various boxes and housing which provide for boththe accommodation of electrical terminations as well as communicationterminations. Examples of outlet boxes which house electricalterminations and also support communication terminations are shown, forexample, in U.S. Pat. Nos. 5,354,953; 5,646,371; and 5,598,998. As seenin these patents, the electrical termination is separated from thecommunications terminations by a solid wall. Typically, this wall isformed by the outside wall of the box which houses the electricalterminations where the electrical terminations are held inboard of theoutlet box and the communications terminations are supported outboard ofthe outlet box.

Common practices and the need to use standard uniform components tocover the outlet box and provide for the ability to readily interconnectto the terminated wires requires that the distance between theelectrical termination and the communications termination be fixed.Also, relevant electrical codes dictate the minimum distance that thereceptacle need be spaced from the side walls of the outlet box. In theelectrical outlet boxes, the art has seen the need to increase the totalinterior capacity of the box so as to accommodate larger numbers ofwires and terminations. With respect to dual voltage boxes, it hasbecome difficult to simultaneously increase the usable interior space ofthe electrical outlet box while maintaining proper spacing between theelectrical termination and the communications termination. Attempts toadjust the receptacle within outlet box may result in the receptaclebeing positioned either too close to one of the side walls or outsidethe required distance from the communications termination.

It is, therefore, desirable to provide electrical outlet box whichprovides increased capacity meets applicable code requirements and whichis capable of accommodating dual voltage terminations.

SUMMARY OF THE INVENTION

The present invention relates to a single gang electrical outlet boxassembly for accommodating a single electrical fixture such as a switchor receptacle. The outlet box assembly also provides for supporting acommunication fixture such as a data plug. The outlet box assembly has agenerally rectangular electrical box having a first side wall spacedapart from a second side wall. The pair of spaced apart side wallsdefine a first mounting axis therebetween, the first mounting axis beinggenerally parallel to the first and second side walls and provides formounting an electrical fixture thereon. A supporting structure foraccommodating a communication fixture extends from the first side walland possesses a second mounting axis which is generally parallel to thefirst side wall. The first mounting axis for the electrical fixture andthe second mounting axis for a communication fixture are substantiallyequidistant from a center line of the first side wall. The firstmounting axis is closer to the first side wall than to the second sidewall.

The present invention also provides for a multigang outlet box assemblyfor accommodating plural electrical fixtures such as switches and/orreceptacles and also for supporting a communication fixture such as adata plug. The multigang outlet box assembly has a generally rectangularelectrical box having a first side wall spaced apart from a second sidewall. The pair of spaced apart side walls supports an electrical fixturetherebetween, the fixture being mounted on a first mounting axisadjacent the first sidewall. The rectangular electrical box of themultigang outlet box also provides for a second electrical fixturemounting axis adjacent the second side wall. Both the first and secondmounting axes are generally parallel to the first and second side walls.A support structure extends externally from the first side wall of therectangular electrical box. The support structure is used foraccommodating a communication fixture along a third mounting axis, thethird mounting axis being generally parallel to the first side wall. Thefirst and third mounting axes are substantially equidistant from acenter line of the first side wall. The first mounting access is closerto the first side wall than the second mounting axis is to the secondside wall.

The present invention further provides for a single electrical gangoutlet box for accommodating an electrical fixture such as a switch,receptacle or the like. The box has a generally rectangular housinghaving a back wall, a perimetrical side wall extending from said backwall, and an open front face. The back wall, perimetrical side wall, andopen front face define a box interior for accommodating a fixture. Theperimetrical side wall includes top and bottom walls and opposed sidewalls. Each of the top and bottom walls includes mounting members forsecuring a fixture to the housing. The mounting members are alignedalong an axis generally parallel to the side walls. This mounting axisis closer to one of the side walls than to the other side wall foroff-center mounting of the fixture in the housing interior.

The present invention still further provides for a single gangelectrical outlet box assembly for supporting an electrical fixture anda communication fixture. The electrical fixture may be a switch or areceptacle or the like and the communication fixture may be a plug suchas a data plug, coaxial connector, or a fiber optic connector. Theoutlet box has a box interior defined between a first side wall and asecond side wall for supporting an electrical fixture within the boxinterior. A support structure extends from the first side wall foraccommodating the communication fixture. The outlet box includeselectrical fixture mounting members spaced apart along a first axisbetween and generally parallel to the first and second side walls. Thesupport structure includes communication fixture mounting members spacedapart along a second axis. The second axis is also parallel to the sidewalls. The first and second axes are generally equidistant from thefirst side wall. The first axis, however, is non-centrally locatedbetween the first and second side walls.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of the dual voltage electrical outletbox of the present invention.

FIG. 2 is a front plan view of the dual voltage box of FIG. 1.

FIG. 3 is a side elevational showing of the dual voltage box of FIG. 1.

FIG. 4 is rear perspective showing of the dual voltage outlet box ofFIG. 1.

FIGS. 5 and 6 are schematic representations of single gang and multiplegang outlet box of the present invention.

FIG. 7 is a schematic of a single gang outlet box showing certaindimensions standardized by the National Electric Code.

FIG. 8 is a schematic of a multiple gang outlet box showing certaindimensions standardized by the National Electric Code.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The dual voltage electrical outlet box assembly 10 of the presentinvention provides for the accommodation of both electrical fixtures(not shown) such as switches or receptacles and a communication fixture(not shown) such as data plugs, coaxial connectors, fiber opticconnectors and the like which provide for termination of voice, data orsignal wires.

Outlet box assembly 10 may be formed of a wide variety of materials asis well known in the art. In the particular example shown herein, boxassembly 10 is formed of integrally molded plastic. Box assembly 10includes an electrical outlet box 12 which is generally a rectangularmember having a back wall 14, a pair of spaced apart side walls 16extending from back wall 14, and opposed top and bottom walls 18 and 20forming a perimetrical side wall 21. Back wall 14, side walls 16 and topand bottom walls 18 and 20 form a box interior 22 having an open frontface 24 which accommodates therein an electrical fixture.

As is well known in the art, outlet box 12 may include one or moreaccess openings 26 which permit entry of electrical wires and cables(not shown) into box interior 22. The exterior surfaces of top andbottom walls 18 and 20 may include mounting flanges 28 which allow thebox to be secured to a building stud or the like in conventional fashionby use of a fastener such as a nail or screw. Top and bottom walls 18and 20 include opposed inwardly directed mounting elements 30 eachhaving a central screw threaded aperture 32 therethrough. The mountingelements 30 permit the attachment of electrical fixtures within theinterior 22 of box 12 in conventional fashion. The location of mountingelements 30 and the screw threaded aperture 32 will be described infurther detail hereinbelow.

Box assembly 10 further includes an externally supported frame 40attached to one side wall 16 of box 12. Frame 40 is generallyrectangular and is positioned in flush relationship with the open frontface 24 of box 12. Frame 40 includes opposed upper and lower spacedapart legs 42 and 44 and a joining strut 46 extending between the distalends of legs 42 and 44. The upper and lower legs 42 and 44 along withstrut 46 and adjacent side wall 16 of box 12 define the rectangularframe 40. The upper and lower legs 42 and 44 of frame 40 includemounting elements 48 which are inwardly directed and include screwthreaded apertures 49. The mounting elements 48 and screw threadedapertures 49 permit accommodation of a face plate (not shown) whichsupports a communications termination device generally centrally locatedwithin frame 40.

Side wall 16 further includes outwardly directed cable holding flanges50 and 52 which extend within the interior defined by frame 40. Cableholding flanges 50 and 52 are designed to accommodate and supportcommunications wires prior to termination to the communicationterminations. Also, strut 46 supports a pair of outwardly extending tabs55 for supporting the wallboard within which assembly 12 is positioned.

The manner in which box assembly 10 support electrical terminationdevices as well as communication termination devices and the ability tosupport an appropriate cover thereover is shown in further detail inU.S. Pat. No. 5,354,953, issued Oct. 11, 1994, and entitled “CableHolding Device”, the disclosure of which is incorporated herein for allpurposes. As is particularly shown in the '953 patent, the plate placedover the outlet box provides access to a duplex receptacle as well as adata jack. As a conventional cover is placed thereover, the center lineof the duplex connector as well as the center line of the data plug mustbe spaced apart a fixed distance. Furthermore, with regard to the outletbox portion 12 of box assembly 10, certain distance requirements aredictated by applicable codes. These distances are shown in FIG. 5 withrespect to a single gang box and in FIG. 6 with respect to a multiplegang outlet box.

Referring now to FIG. 5, the ability of the present invention to providean outlet box assembly 10 for accommodating electrical fixtures so thatthe outlet box has an extended capacity, yet meet the conventionalrequirements dictated by applicable codes and accommodate theconventional requirements of power/communication terminations are shownschematically with respect to FIG. 5.

Box 12 is represented by the left-hand rectangle while frame 40 isrepresented by the right-hand rectangle. The arrangement of the mountingelements 30 of box 12 and mounting elements 48 of frame 40 is such thatvertical mounting axes and x₁ and x₂ are defined. The distance betweenthe mounting axes denoted as a₃ is fixed based upon the requirements ofcomponents such as cover plates which must be placed over the mountedelectrical fixtures as well as the communication fixtures. In order toprovide an expanded interior for box 12, mounting axis x₁ of box 12 ispositioned closer to common wall 16 a than the opposed side wall 16 b.Thus, as shown in FIG. 5, a₁ is less than b. However, as required by thedictates of, for example, the cover plate, common wall 16 b must beequidistant between both mounting axes x₁ and x₂ such that a₁ is equalto a₂, and a₁+a₂=a₃. Common wall 16 a is defined as being generallyequidistant between the mounting axes x₁ and x₂. However, as may beappreciated, the common wall 16 a has a certain thickness. Manufacturingtolerances may be such that due to variations in the thickness of thewall, one surface of the wall may be closer to one of the axes than theother surface is to its adjacent axis. However, absent suchmanufacturing tolerances, the present invention provides for the commonwall to be generally equidistant between the two mounting axes. As usedherein throughout, the phrase “generally equal” or “generally orsubstantially equidistant” takes into consideration such manufacturingtolerances.

The axes x₁ and x₂ must be maintained at a certain minimum distance fromcommon wall 16 a. Axis x₁ must also be a fixed distance from axis x₂.Therefore, increased interior volume of box 12 is accommodated byextending the distance between axis x₁ and the opposite side wall 16 b.Thus, axis x₁ and, therefore, the mounting apertures which define theaxis, is off-centered with respect to box 12, the axis being closer toone side wall than the side wall.

Referring now to FIG. 6, the present invention may be practiced in amulti-gang box configuration. A multi-gang box assembly 10′ includes anoutlet box 12′ and frame 40′. Box 12′ accommodates two electricalfixtures and is defined by a pair of side walls 16 a′ and 16 b′. As withthe embodiment of FIG. 5, mounting axes y₁ and y₂ are defined formounting a pair of electrical fixtures. Frame 40′ is defined by theright-hand rectangle outboard of side wall 16 a′. A mounting axis y₃ isdefined with frame 40. As with the embodiment of FIG. 5, side wall 16 c′is located substantially equidistant between mounting axes y₁ and y₃. Inorder to provide extra capacity for box 12′, mounting axis y₂ ispositioned so that its distance d₄ from its adjacent side wall 16 b′ isgreater than d₂, the distance of mounting axis y₁ from its respectiveside wall 16 a′.

Having described the particular embodiments of the invention herein, itshould be appreciated that modifications may be made thereto withoutdeparting from the contemplated scope of the invention. Accordingly, theembodiments described herein are intended to be illustrative rather thanlimiting, the true scope of the invention being set forth in the claimsappended hereto.

1. An electrical outlet box assembly for accommodating an electricalfixture and a communication fixture in side by side relationship, saidassembly comprising: a generally rectangular electrical box having anelongate first side wall spaced apart from an elongate second side wall,said first and second side walls defining a first mounting axistherebetween generally parallel to said side walls which mounts saidelectrical fixture; and a supporting structure extending externally fromsaid first side wall for accommodating which accommodates acommunication fixture defining a second elongate mounting axis generallyparallel to said first mounting axis; said first and second mountingaxes being generally equidistant from and on opposite sides of saidfirst side wall, with said first mounting axis being closer to saidfirst side wall than said second side wall.
 2. An outlet box accordingto claim 1 wherein said electrical box further comprises a back wallextending between said first and second side walls.
 3. An outlet boxaccording to claim 2 wherein said electrical box further comprises a topwall and a bottom wall connecting said first and second side walls. 4.An outlet box according to claim 2 wherein said back wall furtherincludes access openings adjacent said first and second side walls. 5.An outlet box according to claim 3 wherein said top and bottom wallsfurther include mounting flanges on an exterior surface of said top andbottom walls.
 6. An outlet box according to claim 1 wherein saidelectrical fixture is selected from the group consisting of switches andreceptacles.
 7. An outlet box according to claim 1 wherein saidcommunication fixture is selected from the group consisting of dataplugs, coaxial connector, and fiber optic connectors.
 8. An outlet boxaccording to claim 1 wherein said supporting structure comprises anupper leg spaced apart from a lower leg, said upper and lower legsconnecting said first side wall to a joining strut extending betweendistal ends of said upper and lower legs.
 9. An outlet box assemblyaccording to claim 8 wherein said upper and lower legs further comprisemounting elements located along said second mounting access.
 10. Anoutlet box according to claim 1 wherein said first side wall furthercomprises cable holding flanges.
 11. A multigang outlet box assembly foraccommodating plural electrical fixtures and for supporting acommunication fixture, said assembly comprising: a generally rectangularelectrical box having a first elongate side wall spaced apart from asecond side wall which supports said electrical fixtures therebetween,said electrical box defining a first electrical fixture mounting axisadjacent said first side wall and a second elongate electrical fixturemounting axis adjacent said second side wall, each of said fixturemounting axes being generally parallel to said side walls; and a supportstructure externally extending from said first side wall whichaccommodates a communication fixture defining a third elongate mountingaxis generally parallel to said first and second mounting axes; saidfirst and third mounting axes being generally equidistant from and onopposite sides of said first side wall, with said first mounting axisbeing closer to said first side wall than said second mounting axis isto said second side wall.
 12. A multigang outlet box assembly accordingto claim 11, wherein said electrical box further comprises a back wallextending between said first and second side walls.
 13. A multigang boxaccording to claim 12, wherein said back wall further comprises a topwall and a bottom wall connecting said first and second side walls. 14.A multigang box according to claim 12, wherein said back wall furtherincludes access openings adjacent said first and second side walls. 15.A multigang box according to claim 13, wherein said top and bottom wallsfurther including mounting flanges on an exterior surface of said topand bottom walls.
 16. A multigang box according to claim 11, whereinsaid electrical fixture is selected from the group consisting ofswitches and receptacles.
 17. A multigang outlet box according to claim11, wherein said communication fixture is selected from the groupconsisting of data plugs, coaxial connector, and fiber optic connectors.18. A single gang electrical outlet box assembly for supporting anelectrical fixture and a communication fixture, said assemblycomprising: an electrical outlet box having a box interior definedbetween a first side wall and a second side wall which supports saidelectrical fixture within said interior; and a support structureextending from said first side wall which accommodates saidcommunication fixture; said outlet box including electrical fixturemounting members being spaced apart along a first axis between andgenerally parallel to said first and second side walls; said supportstructure including communication fixture mounting members being spacedapart along a second axis exterior and generally parallel to said firstside wall; said first and second axes being generally equidistant fromsaid first side wall; said first axis being non-centrally locatedbetween said first and second side walls.